How to connect the generator yourself

How to connect a mini-power station to automation. A practical guide.

This article is intended for those who want to connect the gas generator to the ABP unit without outside help (see ATS automation for generator) But, before you start connecting the generator to the automation, you need to know a little about the device and the principle of operation of the generator.

There is no sense in thoroughly understanding the device and the principle of operation of mini-power plants, this information on the Internet is more than enough, we just need to understand how the generator works, where you need to connect the control wires from the autostart system. That is, only practical information, without unnecessary theory and "water."

This method of connecting the generator is suitable for most single-cylinder generators up to 5-6 kW equipped with an electric starter.

So, for starters, consider how a gas generator starts up.

Before starting the engine, it is necessary to close the air damper, turn the ignition key to the "START" position. After the generator engine has started, open the air damper, let the generator warm up for a minute or two, connect the load. To stop the generator, we need to turn the key to the “OFF” position. All.

Now let's try to figure out where we need to connect the wires so that we can control the mini-power station remotely, using the autostart system.

First, let's figure out how many wires are needed to control the mini-power plant. For most gasoline generators up to 5-6 kW, depending on the generator model, 4-6 wires are enough:

1) Start

2) Stop (Ignition)

3) + battery

4) - battery

5) Air damper control. Some ABP models require 2 wires to control the choke.

The very first thing that comes to mind is to duplicate the ignition switch. That's right, we take a tester, ring the necessary contact groups of the ignition switch, and connect the ABP control relays in parallel to it.

But, there is one small BUT ... With this method of connection, the generator is automatically removed from the warranty, as there was an intervention and a change in the design of the generator. And it becomes clear right away, during the initial inspection of the generator. Accordingly, this connection method is not entirely suitable for us. In addition, there is an easier way to connect without interfering with existing generator wiring.

1) First, connect the wires “+” and “-” to the battery terminals. (paragraph 3.4)

2) On the starter, more precisely, on the starter's retracting power relay, parallel to the control wire (thin) from the ignition switch, we connect the wire from the ABP responsible for starting the generator. (item 1)

3) All generators are equipped with an oil level control system. Mostly it is a float system. If the oil drops below normal, the float contact closes on the generator housing. A special relay mounted on the generator block closes the ignition coil, the generator stalls. In our case, we use this relay to stop the generator. To do this, connect the “ignition” wire to the wire from the oil level sensor. (item 2)

Attention. All connections are made using special connectors that can be found in any car shop.

As a result, we got four wires to control the generator. Now, in order to start the engine of the generator we need to close the wires “+” and “starter”. To stop the engine, close the battery “-” wire and the wire from the oil level sensor.

All this is connected according to the scheme of the autorun system. We connect the starter to the terminals “NO” of the starter relay, ignition (stop) we connect to the “NC” terminals of the ignition relay.

Sergey Seromashenko

See also: How to automate the process of turning on and off the generator